Trouser Quality Manual for Subject Apparel Quality Control

2. Objective

3. Cost and Quality

4. Management Responsibility

5. Purpose

6. Scope

7. Organisational Structure and Responsibilities

8. Job Description of Responsible Persons For Quality

9. Quality System

10. Purpose

11. Scope

12. Quality System Procedures

13. Quality Planning

14. Receiving Inspection

15. Purpose

16. Scope

17. Receiving Inspection

18. Accessories

19. Fabric Inspection

20. Fabric Inspection Procedure - 4 Point System

21. Rolls Selection Procedures

22. Acceptable Penalty Points

23. Acceptable Point Count Level

24. Rejection Rate

25. Running Defects

26. Process Inspection

27. Purpose

28. Scope

29. Process Inspection

30. Spreading Inspection

31. Cutting Inspection

32. Sewing Inspection

33. Table Inspection

34. Two Hourly Inspection

35. Final Inspection

36. Purpose

37. Scope

38. Activities

39. Garment Inspection Procedure

40. Defects Classification List (Major)

41. Defects Classification List (Minor)

42. Sampling Techniques

43. Pre-Shipment Survey By Acceptance Sampling

44. Control Of Non-Conforming Products

45. Purpose

46. Scope

47. Activities

48. Garment Taken: PETERENGLAND Formal Trouser

49. Sampling of Formal Trouser

50. Front View

51. Back View

52. Parts of Formal Trouser

54. The most competitive pricing in the world market

55. Shortest lead-time with on time delivery

57. To provide better quality of products and service

58. To provide good and safe working environment to the workers, which includes human value, respect, justice, cleanliness, discipline and equality between workers and others

60. Regular training session is being conducted on Statistical Quality Control System

61. Introduce it as a tool to achieve the goal.

62. Introduce incentives for inspectors and operators for the best performing line.

63. Introduce operators' quality performance chart to find out source and type of defect for taking preventive and corrective measures.

64. Reorganize process/7pcs inspector’s job allocation, work procedure to make them more accountable for effective control on process inspection with the help I-operators quality performance chart.

65. Weekly defect analysis of process inspection, table inspection and final inspection to find out the irregularities of inspection if any and. to take corrective measures.

66. Monthly defect analysis and moving average, line and factory wise, to monitor improvement and trend of defect.

68. Stages at which checks are to be carried out

69. Methods to be followed in conducting the checks

70. Frequency of the checks

71. Criteria for acceptance/rejections

72. Related documents to be checked

73. Documents to maintain as evidence of the checks

75. Check lot size and label against the submitted packing list.

76. Randomly draw 10% of the lot.

77. Delivery of less than 1000 yds – 100% inspection

78. Delivery of 1000 yds to 10000 yds to inspect at least* 1000 yds.

80. The knit dyeing unit is required to present the inspector with a shipment packing list when 80% of the rolls are packed from which the rolls to be inspected will be chosen.

81. Once the inspector has selected the rolls for inspection; no adjustment may be made to the number of rolls to be inspected or to the rolls selected for inspection.

82. At no time during the inspection may any yardage be removed from any roll other than for recording and measuring shade tolerances.

84. Severe defects are assigned max 4 points for each yard

85. Any hole and any running defect will be penalized 4 points

90. Any roll found to contain defects, in any increment of one hundred yards, with an average of more than one major defect per ten linear yards will be rejected.

91. No roll shall be accepted that contains a major defect in the first or last three yards of the rolls. A major defect is considered to be any three or four point defect

93. Rolls paving a measurement of less than the specified width will not be accepted.

94. For knit fabric, rolls having a measurement of 1" wider than the specified diameter will not be accepted. But for the stretched woven fabric, it can be accepted 2" wider than the specified purchased width.

96. Cutting Inspection

97. Sewing Inspection

98. Table Inspection

100. Ends

101. Leaning

102. Tension

103. Narrow goods

104. Remnants

105. Counts

106. Ply height

107. Marker Placing

109. Spec sheet

111. Put arrow sticker on the defect position.

112. Classify defects as major and minor and score accordingly.

113. If the total points, each major=10 and minor=0.5 exceed the prescribed points as per desired AQL reject the lot.

114. Complete data sheet of both visual and fit, take signature from the factory representative on the sheet.

115. Replace defective garments in the carton by good-garments.

119. 1 sample counter

121. 1 sample counter

123. 1 sample counter

125. 1 sample counter

127. 1 sample counter

129. On waist band

130. 2-on side pocket & one back pocket

131. Zipper used

132. What actually being checked

133. In Proto Sample

134. Styling

135. Pattern

136. Measurements

138. Fit

139. Constructional features

140. Type of stitching & quality

142. Fit

143. Constructional features

144. Type of stitching & quality

148. Quality of stitches

149. Quality of seams <br />Front View<br />Back View<br />Parts of Formal Trouser<br />Waist band width 1.5”Waist band 28”Front raise9”Fly length6” Fly width1.6” Position from Waist band 0, from side seam 6.2 Pocket opening6.8” Position from Waist band 0, from side seam 0 Thai width21.5”Leg opening18”Welt 4.9*0.4 Back raise 14”Back pocket 7.2*5” Position from Waist band 2.5, from side seam 1.2 Belt loop 2.2*0.5”Pocket bag9.7*6.7”Zipper length 7”Size label 0.5*0.5” On the right side of the fly below the waist band Brand label 1.1*0.5” 1.5” inch below from waist band Wash care label1.5*1.2” Right side of the front part inside Total length 40” <br />Conclusion<br />Conclusion<br />Quality has always been a primary requirement and considers being the life of a garment. There is no denying the fact that we have been following Quality Control System in the production process since its birth but there might have been differences in those applications in factories. Compiling this quality manual is a humble effort to put almost all necessary details of Quality Control System to ensure that all our factories have a written Manual/ Guideline in black and white to follow. In the beginning we will not concentrate on the statistical Quality Control System. We will follow this after a while when we have enough and required manpower to exercise that. Any positive inclusion in this manual which will help the factories in improving quality is always welcome; but has to done with prior approval from the Managing Director. We all need to educate and train our work force in line with this Quality Manual to try and streamline our quality system. Our united and sincere effort only can help to improve in the sector of quality.<br />